Sunrise Medical EMERALD Workshop Manual Download Page 4

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IMPORTANT

It is potentially hazardous to fit or use any parts other than genuine

Sunrise Medical parts.

The company disclaims all liability for the consequences of such use,

which in addition, voids the machine warranty.

This vehicle is for the carriage of

ONE PERSON

And must not be used for any other purpose.

Summary of Contents for EMERALD

Page 1: ...Workshop Manual EMERALD 4 WHEEL EN G LISH Scooters ...

Page 2: ......

Page 3: ... of EEC directives 89 336 EEC CE CONTENTS Product Information 1 1a Safety Information 2 3 Recommended Tools 4 Service Inspection 5 Technical Specifications 6 Front Wheels 7 9 Rear Wheels 10 Tyres Tubes 11 12 Seating 13 16 Seat Stem 17 Batteries Charger 18 Separating the Scooter 19 Rear Drive Assy Ties Plugs 20 Rear Lights 21 22 Main Control Box 23 Drive Train Assy 24 26 Motor Brake Assy 27 28 Rear...

Page 4: ...y parts other than genuine Sunrise Medical parts The company disclaims all liability for the consequences of such use which in addition voids the machine warranty This vehicle is for the carriage of ONE PERSON And must not be used for any other purpose 1a ...

Page 5: ...ries are disconnected from the vehicle before com mencing work Always check that the battery charger is disconnected from the vehicle batteries be fore commencing work Do not smoke Keep batteries away from all sources of ignition Do not place objects on the battery tops Always try to keep someone within earshot of your work area so that they may come to your assistance if needed Always wear person...

Page 6: ...ssential that correct lifting techniques be employed when moving batteries around It is also recom mended that safety footwear be worn When disposing of old batteries please ensure that correct disposal procedures are followed Contact your local authority for their recommendations Battery Chargers Remember battery chargers are Mains Driven Units Always observe all guidelines and laws relating to m...

Page 7: ...le Spanner 13 Combination pliers 14 Ciclip pliers 15 Hammer small large 16 Soft hammer rubber hide or nylon 17 Feeler gauges metric imperial 18 Stanley knife 19 Pin punches 20 Electric drill mains battery 21 Drill bits metric imperial 22 Hacksaw standard junior 23 Toque wrench 24 Steel engineering rule 25 Tape measure 26 Tyre pump 27 Tyre pressure gauge 28 Personal safety gear 29 Wire strippers cu...

Page 8: ...Physical Inspection Emergency Stop Connections Left Turn Discharge Test RightTurn Up Down Slope Wheels Tyres Over Obstacles Parking Brake Wear Pressure Pneumatic Only Bearings Where appropriate Wheel Nuts Castors Where appropriate StubAxles Motors Wiring Noise Connections Brake Brushes Chassis Condition Welded Joints etc Steering Twists etc Upholstery Seat Seat Back Arm pads Seat Slide Mechanism w...

Page 9: ...6 km Speed 6 mph 9 5 kph Turning Radius 55 140 cm Weight excluding batteries 158 lbs 72 kg Battery Capacity 36 AH Adjustable seat height 17 20 43 cm 51 cm Front wheel diameter 11 28 cm Rear wheel diameter 11 28 cm Range given represents test conditions Please note that temperature user weight terrain and battery capacity may affect overall performance TECHNICAL SPECIFICATIONS 6 ...

Page 10: ...13 00mm socket wrench to undo the centre wheel securing bolt 4 Note the use of thread lock on the bolt Be careful not to breath in the powder residue 5 Note the sequence of washer split washer and bolt 6 Make sure the scooter is firmly supported by axle stands or wooden blocks before removing the wheel 7 ...

Page 11: ...re are 4 nuts bolts securing the wheel bearing hub 9 Use a 13 00mm socket to loosen the nuts but do not try to undo them fullyyet 10 The bolt heads are enclose in the hub but will drift upwards as the nuts are loosened 11 Use your thumb to apply gentle pressure preventing the heads turn ing 12 The nuts can now be removed 8 ...

Page 12: ...enclosed ball race bearings 16 Location of the five wheel rim studs The numbers indicate the re tightening sequence 1 3 4 5 17 Before undoing the five wheel rim studs be sure to deflate the tyre through the air valve 18 Use a 5 00mm hexagon wrench to undo each of the studs When re tightening use the sequence shown above 2 9 ...

Page 13: ...chrome hub cap 3 Note that the centre nut has an extra spacer fitted 4 On the rear wheel hub there is a key way cut which corresponds to the key way on the drive shaft 5 Carefully remove the drive key 6 Make a note of the number of shims used behind the rear wheels on each axle 10 ...

Page 14: ...ress the valve pin and let out as much air as possible 3 Use a 5 0mm Hex Key to undo the five rim studs 4 Press down on the tyre with the ball of the hands and use a tyre lever to gently lift the rim away from the tyre 5 Lift the rim away from the tyre 6 View of the wheel with the first rim removed 11 ...

Page 15: ... as before 9 Lift the rim away from the tyre 10 When refitting be sure not to pinch the inner tube between the rims 11 To help avoid pinching with the rim studs half tightened partially inflate the inner tube 12 The inner tube should then seat itself behind both rims Re tighten the studs in the sequence shown previ ously and then inflate the tyre as normal 12 ...

Page 16: ... the seat recline lever upwards 3 Allow the backrest to fold flat 4 Stand behind the seat lift the seat swivel lever up 5 With the seat swivel lever in the up position carefully lift the seat assem bly off the seat stem 6 Loosen the two armrest adjustment knobs 13 ...

Page 17: ... out 8 Turn the seat assy up side down to expose the 4 bolts securing the swivel pate 9 Use a 13 00mm socket wrench to undo the nuts 10 Remove the nuts washers 11 Lift the swivel plate assy away from the seat 12 This exposes the armrest adjuster bracket 14 ...

Page 18: ...a sturdy 5 00mm hex wrench to undo all four studs Note that these are firmly held some force is re quired 16 The blue thread lock is the reason the studs are so tight 17 Press the seat slide lever down to move the slide to the rear The other slide can be pushed back freely 18 Once the slides are pushed back the other two studs are exposed 15 ...

Page 19: ...se a sturdy 5 00mm hex wrench to undo these 20 They are also held by thread lock 21 Once the studs have been re moved lift off the seat slide 22 And the same with the other side 23 Finally remove the four spacer washers 16 ...

Page 20: ...he scooter 3 Loosen off the Seat Post securing stud There is no need to remove it 4 Un hook the Securing Pin spring 5 Before pulling the Securing Pin out make sure the Seat Stem is held firm because it will drop sharply into the Seat Post once the pin is out 6 Lift the Seat Stem out of the Seat Post 17 ...

Page 21: ...e the batteries lift the seat off 2 Remove the rear cover 3 Undo the two velcro straps that secure the batteries 4 Disconnect the Red the Black battery plugs 5 Carefully lift the batteries out 6 Batteries Battery Leads Battery Charger 18 ...

Page 22: ...lug the Main Loom at the Motor end of the scooter 2 Grab the Securing Pin by the loop at the top 3 Pull the Securing Pin out 4 Pull the front rear sections of the scooter in opposite directions 5 The two sperate sections of the scooter 19 ...

Page 23: ... 2 Release the loom tie holding the main loom 3 Cut the tie wrap holding the Red the Black wires to the rear frame 4 Release the tie holding the Control ler Loom 5 Disconnect the two spade connec tors on the Power Breaker 6 Disconnect the white Motor Plug Remember to press the hook lock down to release the plug halves 20 ...

Page 24: ...ting to one Green socket and one White socket On the other side there is the same but it is a Yellow socket 4 Mark the White plug which goes to the Green socket Yellow on the other side to aid reassembling Do this before disconnecting them 5 Release the tie wrap 6 Carefully squeeze the two securing lugs together using a pair of long nosed pliers 21 ...

Page 25: ...t assembly through the bracket 8 Withdraw the light assembly 9 Mark the position of the indicator or tail lamp if required 10 Note that the rear tail indicator lights are sealed If a bulb blows the complete assembly has to be changed 22 ...

Page 26: ...ooter 3 With the looms clear carefully lift the Main Control Box upwards until it slides off it s guide 4 Aview of the Main Control Box Mounting Bracket 5 A view of the V shaped Control Box Receiver Bracket Note that there are no serviceable parts in the Main Controller If a fault is suspected please return it to Sunrise Medical for repair replace ment 6 The Main Control Box Loom 23 ...

Page 27: ...s securing the Drive TrainAssembly 2 Use a 13 00mm socket to hold the securing nuts 3 On the long drive shaft side use a screwdriver to undo the bolts 4 Remove the two self locking nuts 5 Remove the two bolts 6 Carefully remove the rubber gasket 24 ...

Page 28: ... to undo the nuts on the U bolt side of the drive train 9 Remove the brass bracket 10 Remove the rubber gaiter 11 Carefully lift out the U bracket by moving the Drive Train until the bolts are clear of the frame 12 Be careful not to lose the arched sleeve that is positioned at the inside top of the U bolt 25 ...

Page 29: ...RALD DRIVE TRAIN ASSY 13 Retract the Drive TrainAssy Use caution as this part is heavy 14 The left hand Drive Train fixings 15 The right hand Drive Train fixings 16 The complete Drive TrainAssy fixings 26 ...

Page 30: ...e That may require a cranked hex key or tool 3 Limited room may also require the use of a hex key driver tool If the Drive Train has to be removed do that first and then take the Motor off 4 It is a good idea to mark the top of the Motor and Transaxle for refitting purposes 5 Carefully withdraw the Motor from the Transaxle 6 The Motor Electronic BrakeAssy 27 ...

Page 31: ...ne of the two Motor Brush Housings 9 To inspect the Brushes undo the housing cap using a flat blade screw driver 10 Be carefull not to lose the cap 11 Inspect the Carbon for cracks or excessive wear down Check the Copper terminal and wire for broken connections or green discolouration If any of the above are found replace the Motor Brushes as a set 28 ...

Page 32: ...se a 14 00mm spanner to undo it 3 Check that there are no broken terminals or cracks in the Power breaker body 4 The Power breaker fixings 5 The Rear Suspension Struts 6 The top of one of the struts Note that there are no nuts just a bolt into a threaded housing 29 ...

Page 33: ...t 8 Withdraw the bolt but be aware that if the strut on the other side has been removed the frame top section will drop on its hinges 9 Use the 13 00mm socket to undo the bottom bolt 10 Withdraw the bolt 11 One of the two Rear Suspension Struts 12 The Rear Frame Assy 30 ...

Page 34: ...r away 2 The Orange Main Loom Plug is exposed 3 Depress the plastic lock latch and separate the plug and socket 4 Undo the two screws that secure the Basket Bracket to the front of the Tiller 5 Remove the Basket Bracket 6 Undo screws at the top of the Tiller next to the handle bar on the left 31 ...

Page 35: ...e 3 way molex plug located behind the Tiller Panel 9 Unclip the 2 way molex plug 10 Finally un clip the Blue molex plug 11 Undo the small brass screws that secure the Throttle PCB to the handle bar assy 12 Lift the Tiller Panel away from the handle bar assy 32 ...

Page 36: ...chosen min or max position 16 Use an 11 00mm spanner to partially loosen the securing nut Be careful not to tear the min max decal below When refitting do not over tighten 17 To avoid damage to the min max decal use the fingers to remove the loosened nut 18 Withdraw the Pot Note that there is a low tack glue used on the Pot face It is advisable to use a low tack compound or a star washer when refi...

Page 37: ... Switch have to be de soldered for removal and soldered back on 21 Use a 22 00mm spanner to loosen the Key Switch retaining nut 22 Once loosened it is easier to use the fingers to undo the nut and remove the plastic spacer 23 Withdraw the Key Switch 24 Use a small X head screwdriver for the outer screws on the Charger Socket 34 ...

Page 38: ...ocket assy from the Tiller Panel 27 The two Tiller securing bolts are located just above the TillerAdjust ment Mechanism 28 Use a 10 00mm socket spanner to undo the two bolts 29 The two bolts can be withdrawn easier if the Tiller Shaft is gently rocked back and forth whilst pulling the bolts out 30 Lift the Tiller Shaft off the Tiller Adjustment Mechanism 35 ...

Page 39: ... off its velcro pads 1 Peel up one corner of the carpet to get a good grip 3 This exposes the six body panel screws 4 Undo the six screws 5 Lift off the plastic groove cover 6 Lift up the rubber Tiller Gaiter to expose the two lower fixing bolts 36 ...

Page 40: ...lts 3 Lift up the body panel to expose the front light connections Temporarily rest the panel on the TillerAdjuster to gain access to the plugs 4 Mark the loom plug and socket sides to aid refitting 5 Mark the other side also and disconnect the two plugs 6 Lift the Front Panel clear of the chassis 37 ...

Page 41: ...he Steering Head 2 Pull the Rubber Gaiter off the Main Loom 3 The Front Light Cluster is held in place by mounting springs and screws 4 Note the position of the springs before undoing the self tapping screw 5 Remove the screw and the spring 6 Do the same for the other screw 38 ...

Page 42: ... the back of the cluster 10 Pull the plastic bulb mounts out of the cluster body to access the bulbs 11 To release the bulb gently pull on the glass envelope Take care as the bulb is cap less and the glass and can break 12 Make sure that the copper termi nals do not touch as this will cause a short circuit After changing bulbs always try the lights prior to returning to the customer 39 ...

Page 43: ...1 Front Bumper Fixing 2 Use a 10 00mm socket to undo the nut When refitting do not over tighten 3 The nut spring washer and large washer 4 The Front BumperAssy 5 Overview of the Tiller Parts 6 Overview of the Front Body Panel parts 40 ...

Page 44: ...rough the hole in the front chassis member 3 Retract the plug through the hole at the back of the front chassis member and remove the Main Loom 4 The two front Suspension Struts and the two nuts securing the Steering Cover 5 Use a 10 00mm socket to undo the two nuts 6 Lift the Steering Cover away from the chassis 41 ...

Page 45: ... each Steer ing Rod 2 Use a 13 00mm socket to undo the self locking nut 3 Drop the rod away from the Steer ing Head and lift the spacer off 4 Remember to make a note of the spacer positions to aid refitting 5 The connection with the left hand StubAxle 6 Use a 13 00mm spanner socket to undo the bolt and self locking nut 42 ...

Page 46: ...ut of the StubAxle 8 Lift the small spacer off 9 Withdraw the bolt 10 Use a 13 00mm spanner socket to undo the bolt and self locking nut on the other StubAxle 11 Drop the rods away from the Stub Axle 12 Lift the small spacer off the bolt 43 ...

Page 47: ...EMERALD STEERING RODS 13 Separate the two rods 14 Lift the small spacer off the bolt 15 Withdraw the bolt 16 The Steering Rod Set showing the positions of the nuts spacers and bolts 44 ...

Page 48: ... Note that there is a shoulder at the top of the nut 4 The larger Bearing Retaining Nut should undo using hand pressure but mole grips can be used if this is tight 5 Use a pair of thin nosed pliers to remove the top bearings 6 As the Steering Head is lowered the bottom bearings can be seen Note also the position of the Steering Stop Bolt 45 ...

Page 49: ...o the StubAxle nut and square headed bolt 2 Remove the nut 3 Remove the square headed bolt 4 Lift the StubAxle away from its mount Note that there is an adjustable steering stop bolt attached to the Stub Axle 5 Remove the two spacers Repeat the process for the other Stub Axle 46 ...

Page 50: ...e that there is no nut with this bolt as the bolt locates into a threaded hole 2 Remove the Hexagon Flange head bolt 3 Use two 13 00mm spanners to undo the bottom fixing 4 This is a conventional nut 5 and bolt 6 Remove the Suspension Strut Do the same for the other side 47 ...

Page 51: ...EMERALD ASSEMBLY REFERENCE PHOTO s MAIN FRAME ASSEMBLY 48 ...

Page 52: ...EMERALD ASSEMBLY REFERENCE PHOTO s MAIN BODY ASSEMBLY 49 ...

Page 53: ...EMERALD ASSEMBLY REFERENCE PHOTO s TILLER ASSEMBLY 50 ...

Page 54: ...EMERALD ASSEMBLY REFERENCE PHOTO s REAR DRIVE ASSEMBLY 51 ...

Page 55: ...Please use this Wokshop Manual in conjunction with the Emmerald Owners Manual Parts Manual ...

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